Does anyone have experience with extruded aluminum T-slot?

[Regius_049]

1. Any suggestion on brands or T-slot sources? There are lots of different brands ranging from somewhat affordable to ungodly expensive.

I can't really speak to this one as I do not use it in my caging.

2. What kind of material should I use for panels? I'm assuming 1/2" expanded PVC?

I would highly recommend HDPE, or more specifically, seaboard/starboard HDPE. The materials is FDA/USDA ceritified, UV stable, and non-porous (makes cleaning much easier and staining is greatly reduced). It is more expensive than PVC, but better in most respects.

3. Any tips or tricks to working with the material? I'm wondering why no currently manufacturers use T-slot anymore.

Some people still do, but given that t-slot construction is more expensive and not necessarily for a structurally sound cage, most deem it not worth it. Reptile edge still makes cages akin to t-slot as well as Dragon Stand. I admit they look nice, but look like the seams would be difficult to seal.